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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Advancement of Certification Methods and Applications for Industrial Deployments of Components Derived from Advanced Manufacturing Technologies

One goal of the Advanced Materials and Manufacturing Technologies subprogram, within the Department of Energy’s (DOE) crosscutting technology development program, is to advance the qualification and certification of parts and components created via additive manufacturing (AM). AM offers a new paradigm for the design and optimization of new nuclear components, and for observing and tracking manufacturing performance and potential defects in a way that is not possible with traditional approaches. Tracking and evaluating these in situ data can lead to the estimation of local material properties and, with the use of engineering analysis tools, the estimation of component performance during operation. To achieve these objectives, a digital platform certification approach was developed and is summarized in this report.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Digital Platform Informed Certification of Components Derived from Advanced Manufacturing Technologies

The Transformational Challenge Reactor is being designed at Oak Ridge National Laboratory to demonstrate the feasibility of constructing a reactor core using advanced manufacturing technology. This technology includes additive manufacturing combined with machine learning, materials science, and data science technologies in an effort to facilitate the expansion of additive manufacturing into advanced nuclear energy systems and other applications requiring a high level of quality assurance. The Transformational Challenge Reactor is employing additive manufacturing and artificial intelligence to deliver a new approach. Beginning in FY21, the focus of the program has shifted away from demonstrating a reactor, and instead, towards delivering on four key thrust areas: (1) artificial intelligence-informed design, (2) advanced materials, (3) integrated sensing and control, and (4) the digital platform. Of these four thrust areas, the most pertinent to this report is the digital platform. The digital platform has the potential to be a key enabler for a paradigm shift in how components, those derived from advanced manufacturing technologies, are certified for use in nuclear applications. This is achieved primarily using machine learning to discover correlations from the abundance of data produced through additive manufacturing and those physical properties critical to the performance of the component.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Survey of Modeling and Simulation Techniques for Advanced Manufacturing Technologies Volume I – Predicting Initial Microstructures

This report summarizes the current state of modeling and simulation methods for predicting the initial structure and properties of material in components assembled using advanced manufacturing technologies (AMTs). The report is the first volume in a two-volume series. This first volume focuses on predicting initial microstructures of AM material. The second volume discusses predicting material properties given the initial microstructure. The focus is on technologies of particular relevance to the design and manufacture of nuclear reactor components. The purpose of the report is to help develop the technical knowledge base to support regulatory decisions that will be needed to assess nuclear components manufactured with AMTs as these components are installed at nuclear power plants (NPPs). The report develops a list of AMTs of particular interest to the NRC and summarizes the key microstructural features and corresponding processing parameters relevant to each technology. Further sections describe available physically-based and data-driven prediction methods and survey widely available software tools. The report concludes with a summary of gaps that may be of particular interest to the NRC when evaluating modeling and simulation methods for AMTs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Survey of Modeling and Simulation Techniques for Advanced Manufacturing Technologies Volume II – Predicting Material Performance from Material Microstructure

This report describes the current state of modeling and simulation techniques for predicting the properties of materials fabricated with advanced manufacturing techniques, given the initial microstructure of the material. The report includes a literature survey and a gap analysis outlining and prioritizing key issues in applying these modeling and simulation techniques to nuclear reactor structural materials. The discussion covers both physics-based and data-driven modeling techniques and includes a broad range of manufacturing techniques and materials that may have future nuclear applications. This report is the second in a two-part series, with the first report covering modeling and simulation methods for predicting the initial, as-manufactured structure of advanced manufacturing materials, given a description of the process. Both reports focus on a set of manufacturing technologies likely to be applied to reactor structural components. Taken together, the two reports provide a complete summary of the current state of processing-structure-properties models for advanced manufacturing as well as a survey of applications to reactor structural materials

42 ENGINEERING↗
DOE OSTI2021

TCR Input to NUREG-1537 Process for Advanced Nuclear Technologies Derived from Additive Manufacturing

There has been a renewed interest by several advanced reactor developers to use NUREG-1537 “Guidelines for Preparing and Reviewing Applications for the Licensing of Non-Power Reactors” as a basis for their safety analysis report content and organization. Recently, SHINE Medical Technologies, LLC (SHINE), which is a non-power, Aqueous Homogenous Reactor design radioisotope production facility, received a construction permit based around their NUREG-1537 safety evaluation report (ADAMS No. ML16229A140). Advanced reactor developers are interested in using NUREG-1537 as a basis for their safety analysis report content and organization because of its successful application towards research reactors, graded approach, and simplicity in structure and requirements. However, NUREG-1537 is still largely geared toward light water reactors (LWRs) and many improvements could be made or supported through guidance documents for advanced reactors. For nuclear power to play a role in the future zero-carbon energy portfolio, a supportive regulatory structure is needed to lower regulatory uncertainty and barriers to deployment. At the time of this report, no such document or pathway exists for advanced nuclear technologies, including those derived from nontraditional technology such as advanced manufacturing technology (AMT) and, specifically, additive manufacturing. This report will explore and provide recommendations as to how advanced nuclear technologies derived from additive manufacturing technologies could employ the use of an ISG, other guidance document, or revisions to NUREG-1537 to lower the regulatory uncertainty and barriers for adoption.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Cooperative Research and Development Agreement among National Energy Technology Laboratory, Advanced Manufacturing LLC, and Connecticut Center for Advanced Technology [Abstract]

The National Energy Technology Laboratory (NETL), Advanced Manufacturing LLC (AMLLC) and Connecticut Center for Advanced Technology (CCAT) will collaborate to develop and manufacture cost-effective, oxide dispersion-strengthened, NiCrFeCo-rich high entropy alloys that are superior to Nickel-based superalloys (e.g. IN740) for repair or replacement service in extreme environments. The new alloys can result in higher efficiency and reduced cost of advanced power systems such as advanced ultra-supercritical (AUSC) boilers and gas turbines. High throughput, multiscale computational modeling will be performed to accelerate alloy discovery by interrogating the intrinsic properties of the alloys including thermodynamic, kinetic, and mechanical properties. Validation and evaluation will be performed, including additive manufacturing, microstructure characterization, and mechanical properties tests.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Advanced Materials and Manufacturing Technologies Office

The Advanced Materials and Manufacturing Technologies Office (AMMTO) researches, develops, and demonstrates next-generation materials and manufacturing technologies needed to increase U.S. industrial competitiveness and to advance economy-wide decarbonization. AMMTO supports the national plan to revitalize American manufacturing, secure critical supply chains, and develop diverse innovation ecosystems leading to new manufacturing jobs and increased economic strength and security of the nation. AMMTO provides planning, management, and direction necessary for a balanced program of research, development, demonstration, technical assistance, and workforce development to support domestic manufacturing that is critical to achieving a clean, decarbonized economy.

Next Generation materials and processes, secure an↗
DOE OSTI2022

Scalability Testing Approach for Internet of Things for Manufacturing SQL and NoSQL Database Latency and Throughput

The proliferation of low-cost sensors and industrial data solutions has continued to push the frontier of manufacturing technology. Machine learning and other advanced statistical techniques stand to provide tremendous advantages in production capabilities, optimization, monitoring, and efficiency. The tremendous volume of data gathered continues to grow, and the methods for storing the data are critical underpinnings for advancing manufacturing technology. This work aims to investigate the ramifications and design tradeoffs within a decoupled architecture of two prominent database management systems (DBMS): sql and NoSQL. A representative comparison is carried out with Amazon Web Services (AWS) DynamoDB and AWS Aurora MySQL. The technologies and accompanying design constraints are investigated, and a side-by-side comparison is carried out through high-fidelity industrial data simulated load tests using metrics from a major US manufacturer. The results support the use of simulated client load testing for comparing the latency of database management systems as a system scales up from the prototype stage into production. As a result of complex query support, MySQL is favored for higher-order insights, while NoSQL can reduce system latency for known access patterns at the expense of integrated query flexibility. Here, by reviewing this work, a manufacturer can observe that the use of high-fidelity load testing can reveal tradeoffs in IoTfM write/ingestion performance in terms of latency that are not observable through prototype-scale testing of commercially available cloud DB solutions.

AWS↗
DOE OSTI2024

Advanced manufacturing and digital twin technology for nuclear energy*

Advanced manufacturing techniques and digital twin technology are rapidly transforming the nuclear industry, offering the potential to enhance productivity, safety, and cost-effectiveness. Customized parts are being produced using additive manufacturing, automation, and robotics, while digital twin technology enables the virtual modeling and optimization of complex systems. These advanced technologies can significantly improve operational efficiency, predict system behavior, and optimize maintenance schedules in the nuclear energy sector, leading to heightened safety and reduced downtime. However, the nuclear industry demands the highest levels of safety and security, as well as intricate manufacturing processes and operations. Thus, challenges such as data management and cybersecurity must be addressed to fully realize the potential of advanced manufacturing techniques and digital twin technology in the nuclear industry. This comprehensive review highlights the critical role of digital twin technology with advanced manufacturing toward nuclear energy to improve performance, minimize downtime, and heighten safety, ultimately contributing to the global energy mix by providing dependable and low-carbon electricity.

36 MATERIALS SCIENCE↗
DOE OSTI2025

FY 2025 Multidimensional Data Correlation Platform: Unified Software Architecture for Advanced Materials and Manufacturing Technologies Data Management and Processing

The Advanced Materials and Manufacturing Technologies (AMMT) program continues to advance a data-driven approach to demonstrate the utility of additive manufacturing for fabricating components for nuclear applications. A key scientific goal is to leverage data to better understand manufacturing outcomes and thereby improve the performance, reliability, and lifespan of nuclear components. Ultimately, this effort supports the development of standards for certification and qualification of additively manufactured components, enabling broader industry adoption. In support of this objective, the AMMT program is building and deploying a data management platform to record, index, analyze, and make available the manufacturing data generated across the AMMT program. In FY 2023, the team conceptualized the architecture of the platform and, in FY 2024, deployed the first functional version at the Oak Ridge National Laboratory (ORNL) Manufacturing Demonstration Facility (MDF). In FY 2025, the platform was officially opened to all AMMT members. To enable this expansion, core modifications and enhancements were developed, including improvements to the user interface and workflows for data entry and retrieval. Most notably, robust security and access control mechanisms were implemented to protect data and manage information sharing. This effort featured a logging system, protected views, and controlled access mechanisms. This report documents these enhancements and the transition of the platform into program-wide use.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Advanced Materials and Manufacturing Technologies (AMMT) 2025 Roadmap

The mission of the Advanced Materials and Manufacturing Technologies (AMMT) program is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies in support of the United States (US) leadership in a broad range of nuclear energy applications. The vision of the AMMT program is the expansion of reliable and economical nuclear energy enabled by advanced materials and manufacturing technologies. Four major goals were set to realize the mission and vision of the AMMT program, including: (1) develop advanced materials and manufacturing technologies that have cross-reactor applications, (2) establish and demonstrate a rapid qualification framework that supports diverse materials and manufacturing technology needs, (3) evaluate materials performance in a range of nuclear environments, and (4) accelerate commercialization of new technologies through technology maturation. The program is designed to deliver solutions that support a wide range of reactor technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Advanced Materials & Manufacturing Technology (AMMT): Process understanding for qualifying LPBF 316H SS

Investigations were conducted in fiscal years (FY) 2023 and 2024 to gather relevant data sets addressing challenges related to qualifying 316H stainless steel (SS) for use in future nuclear reactors. This work was a collaborative effort involving researchers from Idaho National Laboratory (INL), Argonne National Laboratory (ANL), and Oak Ridge National Laboratory (ORNL). Key outcomes included: • Development of process-structure-property data sets to better understand the relationships between manufacturing processes, material structure, and performance characteristics. • Establishment of an in-situ monitoring system to link these various data sets together. • Detailed characterization of the raw material feedstock to further strengthen the understanding of process-structure and process-property relationships. Building on this foundation, in FY25 there was interest in exploring the behavior of additively manufactured 316H SS under different test conditions to support the overall material qualification process. Los Alamos National Laboratory (LANL) was tasked with providing specimen samples to the collaborating labs, who then conducted a round-robin study examining factors like selective heat treatment, low-cycle fatigue (LCF), and tensile-creep (T-C) properties. Additionally, high-temperature differential scanning calorimetry (DSC) was performed by LANL to better understand how the material's thermal characteristics change as it is heated up to the melting point. This provided a more comprehensive understanding of the material's behavior. The combined results from these investigations could potentially be used to support the inclusion of 316H stainless steel in Section III, Division 5 of the relevant codes and standards, allowing its use in future nuclear reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Advanced Materials & Manufacturing Technology (AMMT): Development of Additive Manufacturing Agnostic Process Parameter Procedure, 316H Stainless Steel Readiness Level Data Sets, and Machine Maintenance Plan

The University of California, Davis is involved in a project to deploy and enhance an artificial intelligence (AI) system for predicting and preventing plasma disruptions on the DIII D tokamak, under the funding from Department of Energy DE-SC0023500 (title: AI/Deep Learning FRNN Software for Prediction & Real-Time Control of DIII-D Plasma Control System (PCS)). The overarching goal is to demonstrate that real-time, AI-guided intervention can proactively modify the plasma state to avoid or mitigate disruptions—a critical challenge for the future of fusion energy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Interpretation of Ion Irradiation and Neutron Irradiation Damage in Additively Manufactured 316 Stainless Steel using Multiscale Modeling

The accelerated adoption of nuclear energy necessitates advanced manufacturing technologies, such as additive manufacturing, to meet heightened supply chain requirements and support innovative reactor technologies. Due to the unique microstructural characteristics of additively manufactured materials under distinct solidification conditions, comprehensive evaluation of their performance in reactor environments is essential. The Advanced Materials and Manufacturing Technologies program under the Department of Energy's Office of Nuclear Energy focuses on understanding the irradiation performance and damage evolution of laser powder bed fusion 316 stainless steel, with an emphasis on integrating ion and neutron irradiation data to accelerate the development and qualification of materials for advanced nuclear reactor applications. While ion irradiation is a cost- and time-effective method, modeling and simulation are required to interpret the data for the broader range of irradiation conditions encountered in advanced reactors. In fiscal year 2025, integrated multiscale modeling and simulations were conducted to assess irradiation damage in additively manufactured 316 stainless steel. Key outcomes include predictions of chromium enrichment at grain boundaries, nickel enrichment at dislocation cell walls and void surfaces, and heterogeneous void evolution under ion and neutron irradiation conditions. Cluster dynamics simulations revealed the coarsening of voids at high irradiation temperatures and the suppression of void growth by high network dislocation density, while also demonstrating significant growth and coarsening of voids and self-interstitial atom loops at low dose rates. Machine learning-accelerated atomistic simulations highlighted the impact of the local environment and chromium concentration on vacancy diffusivity, providing key insights on the influence of composition on void swelling and radiation-induced segregation. Additionally, molecular dynamics simulations demonstrated the presence of defect production bias and a significant effect of carbon content on defect cluster behavior. These combined efforts aim to predict the performance of additively manufactured materials under various reactor conditions, supporting their qualification for nuclear reactor applications by interpreting ion irradiation data. This report underscores the potential of integrated multiscale modeling to analyze ion irradiation data in the effort to accelerate the qualification of additively manufactured materials for nuclear reactor components.

316 stainless steel↗
DOE OSTI2025

Ceramic High Efficiency Particulate Air (HEPA) Filter Research and Development at Lawrence Livermore National Laboratory

Ceramic high efficiency particulate air (HEPA) filter development program began at Lawrence Livermore National Laboratory (LLNL) over 20 years ago. Historical incidents motivated current safety systems at nuclear facilities. A ceramic filter that can survive a fire can provide robust, passive safety protection. Research has been conducted to improve the safety of nuclear facilities and to reduce operational and lifecycle costs, through ceramic filter technology that can survive fire conditions. Here, the research focused on applications in both new facilities as well as meeting operational requirements necessary to retrofit filters into existing DOE facilities. The research has developed multiple filter technologies spanning traditional HEPA filter materials to advanced manufacturing technologies (e.g., electrospinning, additive manufacturing, etc.). This communication will present highlights of selected development efforts for ceramic HEPA filter research, current state-of-the-art for ceramic filters, and future needs including technical, regulatory, and commercial efforts.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Draft Critical Minerals Evaluation Report: Advanced Materials and Manufacturing Technology

Future energy production by sustainable clean energy technologies will be influenced by the availability and projected supply risks of critical minerals. In this report we discuss this context from the perspective of a sustainable nuclear energy technology and the benefits from the deployment of advanced manufacturing. In the past, the demand of critical minerals in the energy sector was minor, but in recent years renewable energy systems do force a substantial increase in the requirements for critical minerals which further induces pressure on the supply of critical minerals such as chromium, cobalt, nickel, niobium, tantalum, titanium, tungsten, vanadium, and zirconium for nuclear energy technology. The demand of critical minerals for nuclear technology is, besides beryllium and hafnium, minor and less than 1 % of the world supply. This alleviates the negative impact as the nuclear industry may not be able to provide the most compelling priority for the suppliers and to other policymakers looking at the overall needs. In this draft report, detailed background information is provided on the mineralogy of the identified critical minerals, supply chain risks followed by the discussion of specific minerals applicable to material relevant to nuclear energy technology. Briefly, the impact of advanced manufacturing on savings of critical minerals and electric energy is discussed and its effect to nuclear energy technology evaluated. This report will be followed with a final report providing a strategic vision for executable actions to implement the savings through advanced manufacturing, which will be further explored in the upcoming months. The Gen-IV relevant critical minerals will also be evaluated in the context of the AMMT programs material priorities as identified in the material score cards, to determine priorities for future actions. Material savings will become even more substantial when commercial Gen-IV reactor technology becomes available because of their needs for structural materials with higher content in alloying elements for enhanced high-temperature properties and improved corrosion resistance. The requirement for critical minerals in nuclear technology (in kg/MWe) will therefore significantly increase by 2050, even though its contribution to the worldwide electric energy production capacity will remain at about 5 %. The share of nuclear on world’s electric energy production is, on grounds of high utilization and availability 10.2 % and is expected to increase to 12 % by 2050. Advanced manufacturing could aid the deployment of Gen-IV nuclear technology since critical materials savings of up to 30 % seems possible, promoting nuclear energy as a true sustainable clean energy technology together with hydroelectric power.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Advanced Materials and Manufacturing Technologies Nondestructive Examination Efforts at Idaho National Laboratory: Report of FY-24 Efforts

This report details FY-24 nondestructive examination (NDE) efforts at Idaho National Laboratory (INL) in support of the Advanced Materials and Manufacturing Technologies (AMMT) program. While the goal of this endeavor is to develop a multi-modal, multi-length scale workflow for nondestructive characterization of advanced manufactured (AM) nuclear reactor components, substantial development remains until this is a reality. In support of this effort X-ray computed tomography (XCT), X-ray diffraction (XRD), neutron computed tomography (nCT), neutron diffraction, lock-in thermography (LIT), multi-point lock-in thermography (MLIT), and positron annihilation spectroscopy (PAS) were all used on AM specimens to examine defects such as voids, porosity, and residual stress. In addition to summarizing the results of these NDE applications, recommendations for integrating these into a more comprehensive undertaking to promote NDE of engineering-scale components are also included.

36 MATERIALS SCIENCE↗